AP26195367 Development of an automated bioreactor line for continuous production of biogas and fertilizers

- The design of the biogas device and control processes has been developed.

A comprehensive engineering model of the biogas equipment was created with elaborated structural solutions and technological operation logic. Three-dimensional models of components were created, necessary calculations were performed, and a set of technical materials was prepared for transition to production. Integrated processes of automated control of key stages — from substrate supply and preparation to monitoring reaction conditions and discharging the final effluent — were developed. Control systems include intelligent algorithms, sensor monitoring, and adaptive control loops, ensuring stability, safety, and energy efficiency of the biogas plant.

- Patent and information research on biogas devices and manure mixers has been conducted.

A comprehensive analysis of domestic and international patent databases was carried out, including comparison of technical solutions, search for analogues, and determination of the novelty level of the proposed design. An extensive analytical dataset from patent sources was compiled, systematized by solution typology and functional characteristics. Conclusions on the potential advantages of the developed system were drawn, unique structural elements were identified, and promising directions for further R&D were determined.

- Procurement of materials and components for the fabrication of the biogas device has been carried out.

Technical specifications were compiled and refined, and technical assignments were prepared to ensure precise compliance with the parameters of the developed equipment. Necessary material and component items were determined, and the market of available suppliers was checked. Materials were included in the state procurement plan, the completeness of supplies was ensured, and documentation was prepared for timely procurement.

- The design of the biogas device was developed in CAD.

Three-dimensional modeling of all components and assemblies of the device was performed using CAD systems. Structural solutions ensuring manufacturability, ease of maintenance, and operational safety were elaborated. Preliminary engineering analysis of strength and stability was conducted. Technological interaction schemes of components were refined. Visualizations and a set of technical documentation were prepared for transition to manufacturing.

- The biogas device has been fabricated.

A pilot (experimental) model was assembled and tested. Operational tests of the main mechanisms, including substrate intake, gas mixture formation, and functioning of key units, were conducted. Initial experimental data on performance were obtained. Design bottlenecks were identified, and recommendations were made for optimization of the technological process and improvement of mechanical stability.

- Control processes for the closed system of filling the first bioreactor with manure have been developed.

Control algorithms ensuring automated filling of the bioreactor with substrate, considering density, pressure, and flow rate parameters, were developed. Interaction schemes of actuators and sensors were prepared. System operation was modeled under various load conditions. Logical scenarios for operation in emergency and non-standard situations were determined.

- Control processes for the closed system of regulating the bioreactor temperature have been developed.

A regulation system including intelligent adaptive temperature control algorithms was formed. A feedback structure for maintaining stable temperature values was developed. Engineering analysis of the efficiency of various heating and cooling modes was conducted. Proposals for reducing energy consumption while maintaining technological stability were prepared.

- Control processes for the closed system of regulating substrate acidity have been developed.

High-precision algorithms for monitoring and adjusting the pH of the medium using continuous sensors were developed. Reagent dosing mechanisms were optimized. Automated control schemes ensuring long-term stability of the technological process were prepared. Measures to increase measurement reliability and accuracy were implemented.

- Control processes for the closed system of unloading manure effluent from the last bioreactor have been developed.

The complete logical structure of the system operation, including normal, non-standard, and emergency unloading modes, was elaborated. Sensor monitoring schemes for level and pressure were created. The sequence of operations to reduce the risk of system overload was determined. Safety analysis was conducted, and measures were developed to prevent blockages, overflows, and leaks.

- An ultraviolet lamp has been installed in the last bioreactor.

The lamp was mounted considering the requirements for sanitary treatment of the reactor’s internal environment. Power calibration and optimal placement for maximum disinfection efficiency were performed. Test operation cycles of the equipment were conducted to analyze radiation stability, uniformity of treatment, and effects on the microbiological environment. Measures to improve the durability and reliability of the unit were determined.